Enhancing Human Skill by Dojo Training in Manufacturing

 Dojo in Manufacturing :

The latest concern and opportunity that lies in Manufacturing is the under utilization of the human potential of the Blue Collar Workforce.

Blue-Collar Workforce: The Blue-Collar workforce is the spectra of employees that add real value to the Product of a Manufacturing organization. By virtue of the large size of the workforce, the overall Manufacturing cost/conversion cost /quality/safety depends on the Skill Level as well as the value addition done by them.

Lean, Six Sigma, and other tools are good to a large extent while planning for Manufacturing Cost Reduction Projects, but the question still remains: Are We Utilising The Actual Potential Human Skill Of Our WorkForce? If no What Next?

The GOD lies in detail ( and the Devil too). Studies show that the elemental activities ( second by second activity ) done by an operator / a worker, the Work speed (SOP), Quality, and Safety associated with these activities can be improved to a large extent just by inculcating a human- sense based activity alignment.

Some Examples Are As Below :

•  Picking Exact Number of Bolts From the Point to Use Bin
•  Picking Right Nuts / Bolts ( M6 vs M8 ) without seeing
•  Improving Left Right Hands For Parallel Activity
•  Tighten bolts / Nuts without Torque Wrench For Tightening
•  It measures Temperature Without a Thermometer
•  It measures Accurate Length without Scale
•  Measure Vibration by Hand
•  Measure Weight without Balance
•  Place Material in Bins / Slot Without Seeing
•  Select the Right tools/wrench without trial -fit
•  Pick Material with both hands simultaneously (Point of Use)
•  Insert Pin’s Accurately Without Seeing Holes / Slots
•  Balance and Push material in conveyor to Exact Distance
•  Travel Standard Distance inside Shop Floor
•  Estimation and Calculation for Bin’s, Parts, Area, etc.
•  Estimating Circular Rotation with our measuring the Rotation Degree

See this to Believe – https://www.youtube.com/watch?v=Wn4lpt6Rg1I

Recall your childhood when you were learning to ride a bicycle, it was difficult to ride / pedal without seeing the pedals. But once you rode it for some days you never-ever needed to see the pedal. Have you ever thought that this level of expertise can be developed?